Apparatus for manufacturing fiberboard



Nov. 26, 1940. H. A. SHEESLEY APPARATUS FOR MANUFACTURING FIBERBOARD 1,1936 5 Sheets-Sheet 1 Filed Dec.

van ham ATTORNEY Nov. 26, 1940.

H. A. SHEESLEY APPARATUS FOR MANUFACTURING FIBERBOARD Filed Dec. 1, 19365 Sheets-Sheet 2 q k n lNVENTOR W Z a 8J0 MM 1940- H. A. SHEESLEYAPPARATUS FOR MANUFACTURING FIBERBOARD 5 Sheets-Sheet 3 Filed Dec.

INVENTOR Harare 19. Skim/a ATTORNEY Nov. 26, 1940. H. A. SHEESLEYAPPARATUS FOR MANUFACTURING FIBERBOARD Filed Dec. 1, 1956 V 5Sheets-Sheet 4 1 I I I a WU I H I l H 2w WWI I I WM E .wnhllllmnhfiwh EWN F\ lt ATTORNEY 1940- H. A. SHEESLEY APPARATUS FOR MANUFACTURINGFIBERBQARD Filed Dec.

5 Sheets-Sheet ATTORNEY an NQN M an M NN Qua Patented Nov. 26, 1940UNITED STATES APPARATUS FOR MANUFACTURING FIBERBOARD Horace A. Sheesley,Portland, Maine, assignor to Tulide Products Corporation, Portland,Maine,

a corporation of Maine Application December 1, 1936, Serial No. 113,584

8 Claims.

' This invention relates to a method and apparatus for manufacturingfiberboard, and more particularly to an improved method and apparatusfor converting pulp and other fibrous waste into commercially usefulsheets or rolls.

In the manufacture of board materials commonly known as pulp board,cardboard, fiberboard, and paperboard, the so-called wet process ofmanufacture is universally used. In this process, the fiber base, whichmay .be old newsprint, paper waste, or pulp of all kinds, is placed in aheater, where the water and the desired paper sizing and color is added.As it comes out of the beater more Water is added until the liquidcomprises approximately 95% .to 98% water and 2% to 5% fibrous stock..The liquid pulp is then conducted into a Jordan machine, which servesto brush the pulp so as to eliminate any lumpy material and leave theminute pulp fibers freely suspended in the carrier liquid or water. Fromthe Jordan machine the water and pulp fiows onto a paper machine,generally the Fourdrinier or cylinder type of machine. In thepaper-making machine the water must be removed first by draining, thenby suction, and finally by drying over heated drums. The paper is thensuitably calendered orotherwise treated to give the desired surfacefinish.

In the manufacture of pulp board, cardboard, fiberboard and paperboardby the wet process above briefly described, expensive machinery andequipment is necessary, requiring a large invest ment of capital andmuch skilled labor. An enormous amount of clean, pure water having thedesired chemical and physical properties must be supplied,- which watermust be heated in cold climates. The paper-making machine must thenfunction to remove the immense quantity of water from the web, runningfrom 95% to 98% Water. The layman scarcely realizes the tremendousamount of water required in the wet process of making paperboard nowcommonly used. Experts have stated that a mill manufacturing 500 tons ofpaperboard a day requires water in an amount to amply supply a city of40,000 population'. In addition to this huge amount of water and theexpensive equipment andcapital investment necessary, an enormous amountof horsepower is required to drive the heaters, the Jordan machine, thepaper machine, pumps, and other equipment. It is estimated that from4,000 to 5,000 horse-power is required to operate one papermakingmachine including the collateral equipment, such as the heaters, Jordanmachine, pumps and other equipment necessary to supply the papermakingmachine with the wet pulp. This expensive equipment, the capitalrequired, the labor problem, the power consumed, and the water supply,several times exceed the cost of the Furthermore, there is approximatelya ten percent. stock loss in the wet process of board manufacture. Thewet process is now universally used not only in themanufacture of paperfrom the original wood pulp but also in the manufacture of paper andboard from paper waste, such as old newsprint, waste paper and'pulp ofall kinds. 1

It is an object of this invention to provide an improved method andapparatus for the manufacture of such products as cardboard, paperboard, fiberboard, pulp' board, wallboard, and similar sheet material,more economically, more efiiciently, and at a higher rate of productionthan present known processes.

It is further an object of this invention to provide an improved processand apparatus for manufacturing paperboard products and similar sheetmaterial whereby the large amounts of water, the capital and laborrequired, the expensive machines and equipment required, are greatlyreduced, resulting in a product which is fully equal, if not superior,to the product manufactured under the present-wet processes.

Another object of my invention is to provide a dry process for thepreparation of materials or fibers for making paperboard products andlike sheet materials.

Another object of this invention is to provide an improved process formanufacturing paperboard and the like, which is continuous in operationand wherein the raw materials may be fed in at one end and the finishedproduct removed from the other end with a minimum of labor andsupervision.

Another object of this invention is to provide an improved method andapparatus for converting newsprint, paper waste, pulp of all kinds, andother fibrous materials, such as bagasse, into commercially desirableproducts such as paperboard, pulp board, fiberboard, cardboard,wallboard, and similar sheet materials, with a relatively small plantinvestment in machinery and reduced cost over other processes now incommercial use. The fibrous stock is first reduced raw material goinginto the finished product. to a fluffy mass of tangled fibers whileainsubstantially dry condition without the addition of water or otherliquid ingredients. The tangled fibers are then assembled together toprovide a loosely piled web of substantially dry fibers, which web isgiven the desired uniform thickness and the desired width. The fibersare then impregnated with a binder solution, preferably by spraying thedesired amount of binder into the loosely binder to cause the individualfibers to adhere and bind together, into a homogeneous mass. Bindersubstantially in excess of that required to effect the desired bindingaction should preferably not'be projected into the web. The binder ispreferably in liquid or semi-liquid form when projected into the web andmay comprise the usual sizing used in papermaking or other bindermaterials, depending upon the product desired to be produced. Inaddition to the well-known paper sizings, which generally contain suchingredients as starch, resins, caseins, glues, and similar adhesive orbinding materials, I also propose to use such materials as dissolvedrubber, latex, asphaltums, tars, heated sulphur, and other binderingredients either alone or mixed with other constituents.

After the web has been thoroughly impregnated with a binder, theimpregnated web is given a gradually increasing compacting pressure soas to reduce the thickness of the web to approximately the desiredthickness of the finished product. Various surfacing materials, eitherin sheet, liquid or semi-liquid form, may then be applied to one or bothsides of the compressed impregnated web, and the web may then besubjected to drying action to remove the liquid or volatileconstituents. The sheet material can then be cal endered, surfaced, orotherwise treated to give the material the desired finish and surfacetexture. If desired, the coating or surfacing of the board may beapplied either before or after or during the drying thereof, which mayvary in accordance with the material desired to be produced.

The apparatus for carrying out my improved process generally comprises acylinder having a large number of pins or needles arranged on theperiphery thereof, which contact the fibrous material and reduce it to afiufied state. The cylinder with the pins thereon will hereafter betermed a "picker or shredder. The fibrous material, such as newsprint,waste paper, pulp, bagasse, or fibrous materials of any description,whether in small pieces, broken. bits, or large sheets or rolls, are fedto the picker by means of a suitable conveyor, and are continuouslymoved in contact with the shredding needles of the picker by means ofcorrugated feed rolls. The stock is firmly held in compressed positionso as to be acted upon by the picker by means of elements such as shoeswhich rest against the stock, compressing the same and holding the samein a compressed mass while acted upon by the picker. The peripheral orlineal speed of the moving needles will depend upon the nature of thematerial to be shredded as well as the speed of production desired.Generally, the needles, whether mounted on the drum or on a moving beltshould move across the stock at a speed of from 2,000 to 10,000 linealfeet per minute, and preferably for most operations the speed may varyfrom 4,000 to 7,000 lineal feet per minute, which, of course, will varyin accordance with the conditions above specified. Preferably, the pinshave sharp points and are generally maintained in their sharpenedcondition by, the sharpening action which the material itself exertsupon the needles; The needlesmay be spaced fairly closely and yet permita strong mounting therefor, the spacing of the needles preferably notexceeding /2 inch, and a spacing of inch or less is preferable.

Suitable blowers and/or suction devices 'are provided to convey theindividual fibers separated from the stock to the web-forming andequalizing mechanism. Before the web is finally formed the fibrousmaterial may be formed into a temporary mat or web and then given asecond picker treatment to make sure that all particles of the stockhave been shredded and reduced to a loosely piled fibrous condition inwhich substantially each fiber is separated from the other. Suitablescreening or separating apparatus may also be provided to grade the pulpfibers if desired, separating out the dust particles, removing anyparticles or materials which may not be desired in the finished product,which separating operation is preferably performed after the firstshredding operation. Provided the raw material or stock is in the propercondition, such separating treatment is generally unnecessary.

After the fibrous material leaves either the first picker or the secondpicker, as maybe found desirable, the fibers are laid into a continuousweb of substantially dry, loosely piled fibers, which web-formingoperation is performed by what may be here termed a condenser. Thecondenser may comprise a pair of cylindrical members having smallclosely spaced openings or holes in the periphery thereof. A partialvacuum is supplied to the interior of the rolls by means of a suitablevacuum fan or pump, the vacuum generally ranging from 2 to 10 lbs. Thefibers are thus sucked or drawn in matted relationship onto theperforated rotating rolls. One of the rolls, preferably the bottom roll,has a greater vacuum applied thereto so that the forming web will clingto the periphery of one of the rolls only as the web passes between theperforated rolls. The spacing between the perforated rolls may be variedas desired; preferably, the rolls are freely movable so that the toproll rides on the web, serving to compact or depress the same. thicknessof the web is controlled and determined by a suitable control mechanismwhich regulates the amount of fibrous material fed to the perforatedrolls or condenser.

As .a modification, it has been found that a satisfactory condenser orweb-forming apparatus may be formed by the use of one perforated rollonly, which roll is superimposed over a travelling foraminous belt. Thebelt may comprise a foraminous fabric such as canvas, a fine screen suchas Fourdrinier or papermaking wire, or other suitable belting. A partialvacuum may be applied to the underside of the belt so as to draw thefloating fibers between the superimposed perforated cylinder and thebelt to lay the fibers in a continuous web of the desired thickness andwidth. When the belt is used, a greater vacuum pressure is applied tothe belt than to the superimposed perforated 'rolls. Suitable means,such as a peeler blade, may, if desired, be used to strip the web fromthe perforated roll or foraminous belt to which it clings.

The web is conveyed away from the condenser over a suitable belt orplatform and, if desired, the web may be assisted in its movement by Themeans of a pair of draw rolls which are peripherally fluted or roughenedto grip the material. The web then passes onto an apron or carrierconveyor, and then onto a continuous belt of foraminous material such ascanvas, foraminous fabric, or papermaking wire. At this point the bindersolution is applied to the web, preferably by means of spray nozzleswhich project the binder in a fine spray into and through thesubstantially dry, loosely piled fiufied fibrous web. The binder maycomprise any desired material as. for example, papermaking sizing,rubber dissolved in a solvent, latex, glues, caseins, bitumens,asphalts, tars, or other binder materials reduced to liquid orsemi-liquid condition. Where spray devices are used the binder isgenerally projected onto the web with suflieient force to thoroughlyimpregnate the fibers throughout the web, a pressure of from 2 to 25lbs. air pressure being used, depending upon the material to beimpregnated, the nature of the binder, the thickness of the web, and thematerial to be produced. While the binder is most desirably applied tothe web by suitable spray devices, it is contemplated that the web mayalso be impregnated by running the web through a pool of the binderliquid while supported on the conveyor belt.

Suitable pressure means are provided to compress the impregnated web.Such compression should be so executed that the initial interlaced andinterwoven arrangement of the fibers is not disturbed, and slippage ordisturbance of the interlaced and interlocked arrangement of the fiberswhich might result in inherent weaknesses in the finished material,should be particularly avoided. The impregnated web may be initiallycompressed by means of rolls or a continuously moving foraminous beltwhich overlies the continuous foraminous belt supporting the web,previously described. The web is gradually compressed as it movesbetween the upper and lower moving rolls or belts. Where belts are used,they may be suitably supported upon rotatable guide rolls, which, ifdesired, may be adjusted to regulate the spacing between the belts. Theupper belt may also be formed of suitable foraminous material, such ascanvas or textile, or a papermaking screen. While a pair of cooperatingcontinuous moving belts is the preferable mode of initially compressingthe web, it is understood that a stationary platform working inconjunction with a suitable pressure roll or one or more pairs ofpressure rolls, may in certain instances be substituted. Furthercompression means than the compression belts above mentioned may also beused, such as one or more pairs of compression rolls which operate togradually reduce the thickness of the impregnated web to the desiredthickness in such a manner as not to extrude the contained binder withinthe web. At this point in the process one or both surfaces of thecompressed web may be surfaced or surface-treated, as by the applicationof an overlying layer of sheet paper of any desired color, strength orthickness, or textile material. If desired, a surface coating may alsobe applied, such as wood flour, china clay, talc, lacquers, or otherpowdered or semiliquid materials or coatings which are either in thenature of adhesive or which may be secured in position by a suitableadhesive.

The treated web is then run through a suitable dryer, preferably of thetunnel type, which tunnel dryer comprises a suitable room or enclosurehousing one or more conveyor belts which support the web as it movesthrough the tunnel. Suitable heating means may be provided to facilitateand hasten the escape of the liquid and volatile constituents in theweb, derived mainly from the binder or coating material applied thereto.In place of the drying tunnel, heated drying rolls such as commonly usedin papermaking machines, may be substituted if desired. The temperaturein the tunnel dryer or heated cylinders may vary from room temperatureup to 350 F., depending upon the speed of production desired, thematerial treated, and other conditions. Preferably, the heat should bebelow the scorching temperature of the fibrous material in the web. Thetemperature used may also be largely determined by the binderingredients used, and the action of heat on such ingredients. Preferablysufficient heat should be used to effect the desired binding action inthe most economical and expeditious manner and to produce the greatestbinding effect.

It is understood that. where certain materials, such as bitumen,asphalts, tars and similar materials, are used, they may be applied in aliquid condition by heating the material as it passes through the spraynozzles. The compressed impregnated web should then be subjected to acooling action so as to freeze or solidify the binder constituent. Afterthe compressed impregnated web has been given the required heating orcooling treatment necessary to solidify the solid portions of the binderand remove the volatile constituents, the web may be run throughsuitable compression or calender rolls to give the surface of the webthe desired texture and finish.

My improved process and apparatus permits the manufacture of suchmaterials as paperboard, cardboard, fiberboard, pulp board andwallboard, and similar sheet materials by continuous process, whereinthe wet or flotation process of assembling fibers into a continuous webis completely eliminated. The cost of the equipment necessary forcarrying out this process is a fraction only of the cost of theequipment and chemicals required to manufacture similar products underpresent processes. The labor and supervision required is furthermoregeratly reduced. The large volume of water or carrier liquid required inthe wet or flotation process is eliminated, thus completely removing theWater supply problem, the care, chemical analyses and heat required toprovide a suitable water supply, the tanks, equipment, machinery andpumps required to supply the necessary water, thus effecting a saving inthis item alone. Finally, a greatly increased production and output thanfrom a plant of comparable size, greater flexibility of production,elimination of the problem of climatic conditions and raw materialsupplies, are also effected. Since the improved process and apparatusherein disclosed can be carried out economically either at the source ofsupply of the raw material or at the market point irrespective ofclimatic conditions, water supply and other factors inherent inproduction of fiberboard products under present methods.

Various other features and advantages of the invention will be apparentfrom the following particular description and from an inspection of theaccompanying drawings.

Although the novel features which are believed to be characteristic ofthis invention will be particularly pointed out in the claims appendedhereto, the invention itself, as to its objects and advantages, and themanner in which it may be carried out, may be better understood byreferring to the following description taken in connection with theaccompanying drawings forming a part thereof, in which:

Fig. 1 is a top plan view of my improved fiberboard-making apparatus;

Fig. 2 is a side elevational view of the apparatus;

Fig. 3 is an enlarged horizontal cross-sectional view of a portion ofthe apparatus taken along line 3-3 of Fig. 2, this view showing inparticular the feed rolls, picker and associated mechanism;

Fig. 4 is an enlarged longitudinal cross-sectional view of the feedrolls, picker andassoelated mechanism, this view being taken on line 4-4of Fig. 3;

Fig. 5 is an enlarged longitudinal cross-sectional view showingparticularly the conveyor conduits through which the flufied fibers areconveyed, the fans, condenser rolls, equalizer, and the secondary feedrolls and picker, this view being taken on line 5-5 of Fig. 1;

Fig. 6 is an enlarged horizontal cross-sectional view of a portion ofthe apparatus showing particularly the conduits, fans, condenser rollsand drives therefor, this view being taken on line 66 of Fig. 5;

Fig. 7 is an enlarged longitudinal cross-sectional view showing thesecondary condenser which lays the fibers in a smooth and even. looselypiled web of the desired width and thickness, the binder applicator, thesaturated webcompressing mechanism, and the dryer, this view being takenon line '|l of Fig. 1; and

Fig. 8 is a top plan view of the apparatus shown in Fig. '7, certainparts being broken away to illustrate certain features of theconstruction.

Similar reference characters refer to similar parts throughout theseveral views of the drawings and specification.

Referring more particularly to Figs. 1 to 4 inclusive, the fibrous rawmaterial or stock to be processed is positioned upon a suitable carrierbelt which is trained over ,a suitable feed roll. The fibrous materialor stock fed into the m chine may comprise folded newsprint, wastepaper, wood pulp of all kinds, bagasse (the fibrous waste material fromsugar cane), and like fibrous materials, hereinafter called stock. Myimproved process and apparatus is particularly adapted to themanufacture of pulp board, fiberboard, paperboard, cardboard, wallboard,strawboard, and similar boards from such fibrous stock, hereinaftertermed fiberboard. My improved process and apparatus is particularlyadapted for the processing of such stock as waste newsprint and wastepaper which is collected in cities and villages and obtainable fromwaste paper dealers.

In processing stock such as folded newsprint and waste paper, it ispreferably desirable to provide one or more primary feed units in orderthat the finished fiberboard produced may possess the desired width, andthickness or weight per ream. For the purpose of clarity there is shownin the drawings two feed belts l and la, each feeding into a primarypicker 20, although it is understood that any desired number of feedbelts and pickers may be provided to obtain the desired width andthickness of the finished product. The stock s is placed upon the feedbelts l and la by operators who spread the stock as evenly as convenientupon the belt. Each belt I and la may be supported by one or morerollera 2, fixed to shafts 3 suitably journaled in Journals 4 providedin the framework I of the machine.

The stock 8 passes from each of the conveyor belts I and id to a pair offluted feed rolls 0 and I, each of which is provided with longitudinallyextending flutes or channels 0 which serve to rip the stock and compressthe same into a compact mat. It is understood that the surface of therolls 4 and I may be otherwise formed, so as to satisfactorily grip thestock being fed into the machine, as by roughening the exterior thereofor providing small mounds or projections thereon. The feed roll 1 isfixed to a shaft 9 rotating in journals provided in the framework i ofthe machine. The feed roll 6 is fixed to a shaft II which rotates injournals ll so constructed as to permit a limited vertical movement ofthe feed roll 6 to permit the passage of stock of different thicknssesthereunder.

The stock passes from each of the paired feed rolls 6 and I between apair of compressor shoes [2 and I3, which serve to further compress thestock into a hard, firm mat and hold the same in compressed positionwhile being acted upon by the picker 20.

The picker 20 comprises a drum 2| which may be formed either of wood ormetal fixed to a suitable shaft 22 which rotates in journals 23 providedin the framework 5 of the machine. The drum 2| is provided with pins orneedles 24 projecting from the periphery thereof at a distance ofapproximately to 1 The pins must be firmly mounted in the drum shell 2|and should be formed of strong steel so that they will not break off,become loose, or otherwise become deformed. The pins 24 shouldpreferably not be spaced greater than 1" apart and, preferably, theyshould be spaced fairly close together, preferably being spaced or lessapart. The spacing of the pins as well as the length of the pins will,of course be governed to a considerable extent by the stock operatedupon, as well as by the character of the finished board desired to beproduced. The pins should be sharpened at the outer end thereof,preferably to a flat point. Generally, contact of the pins with thestock operated upon will maintain the pins in sharp cutting or pickingcondition. If the pins should wear unevenly, the difiiculty can becorrected by reversing the position of the picker 20, turning itend-for-end so that the other side of the pins will receive the wear.The shaft 22 of the picker is provided with a suitable drive wheel 25fixed to one end thereof. A motor 26 having a pulley wheel 21 attachedto the shaft 28 thereof is operatively connected to the drive wheel 25of the picker by means of suitable belting 29.

The picker drum 2| may be of any desired diameter and length to mostexpeditiously handle the stock. Generally, a drum diameterof from 24" to36" has been found satisfactory. The picker should be of suflicientlength to operate upon the full width of the stock fed to the picker,which stock may vary from 12" upward to 50 or more. In the case offolded newsprint, the picker 2!! may be approximately 18" in width. Thepicker is driven so as to develop a peripheral speed of from 2,000 to10,000 lineal feet per minute. Where newsprint and like paper waste isused as. stock, a speed of from 5,000 to 7,000

lineal feet per minute has produced excellent results.

The feed roll 6 and the pressure block or shoes l2 should be so mountedas to ride freely on the stock. The feed roll I and the block I 3 neednot be vertically adjustable. To each end of the pressure block l2 andthe shaft l0 supporting a feed roll 6, an arm I4 is pivotally mounted.Each arm I4 is provided with a collar l5 pivotally mounted upon aportion of the bearing 23 for a picker shaft 22 fixed to the frame 5 ofthe machine. Another arm fixed to the collar l5 supports an adjustableweight I! and is so arranged as to retain the feed roll 6 and thepressure block l2 in pressing engagement with the stock s. The pressureblock l3 may be fixed to the framework 5 of the machine by means ofsuitable supporting brackets l8. Thus it will be seen that the blocks l2and I3 cooperate to press the stock s therebetween in a firm compactlayer so that the needles 24 can operate to tear loose and reduce thefibrous constituents thereof to a fiuifed fibrous state. It will also benoted that the side wall is of each of the blocks l2 and I3 are slightlyarcuate so as to closely conform to the are described by the outer endsof the needles 24 during rotation, the side walls l9 also beingpositioned as close as possible to the ends of the needles withoutobstructing their movement. Suitable adjustable means may be provided topermit the presser blocks l2 and I3 to be moved closer'towards or awayfrom the outer ends of the needles as they become worn or new needlesinserted into the drum.

The feed roll 6 is also operatively connected or attached to the arms l4which retain the feed roll 6 in pressing engagement against the stock s,or if desired, a separate lever mounting may be provided for feed roll6, which mounting may be similar to the mounting for block I 2. Thejournals ll through which the shafts I ll of the feed roll 6 extend areso shaped and elongated so as to permit floating movement of the feedroll 6 so as to press the stock between the feed rolls 6 and l with thepredetermined pressure.

The feed rolls 6 and 1 may be driven by the motor 26 through suitabledrive mechanism, preferably reduction gearing. There is shown for easein illustration merely the feed rolls 6 and I operatively connected tothe driven shaft 22 of the picker 2!], although it is understood thatappropriate speed reduction means should be previded, since the picker20 rotates many times faster than the feed rolls 6 and 1. For purposesof illustration only I have shown the shaft III of the feed roll 6provided with a sprocket wheel 3| connected to the sprocket Wheel 32fixed to the Shaft 22 of the picker 2!] by means of a suitable drivechain 33. Likewise. the shaft In of the feed roll 6 may be provided witha gear 34 which meshes with gear 35 fixed to the shaft 9 of the feedroll I. the gears 34 and 35 having long teeth permitting verticalfloating movement of feed roll 6 during operation. The supporting rolls2 for the belts l and la may likewise have a sprocket 31 attached to theshaft 3 thereof, which is operably connected to a sprocket 38 fixed tothe shaft 9 of the feed roll I by means of a suitable drive chain 39. Itwill thus be seen that the motor 26 is operably connected to drive thefeed rolls 6 and l and the belt-supporting roll 2 uniformly at theproper speed to feed the stock into operative engagement with theneedles 24 of the picker 20 so as'to pick loose the fibers constitutingthe stock and reduce the same to a fiuffed condition, in which thefibers are substantially individually separated from each other.

Each of the pickers is enclosed by a casing, preferably of sheet metal,which encloses not only the picker 20 but a fan 50 and the feed rolls 6and I. The casing comprises generally a top wall portion 40 and sidewall portions 4| which completely enclose the sides of the picker 20,the fan 50, the blocks II and I2 and the feed rolls 6 and 1. The topwall 40 of the casing is so shaped as to generally conform in arcuatecontour to a peripheral portion of the picker 20, the fan 50, and theupper feed roll 6, as shown in Fig. 4.

The fan 50 may comprise generally a drum or core 5| having horizontallyextending blades 52. The fan 50 may be fixed to a shaft 53 rotatablymounted in bearings 54 provided in the framework 5 of the machine. Thefan shaft 53 may be provided with a suitable sprocket wheel 55operatively connected by a drive chain 51 to a sprocket wheel 56attached to the picker shaft 22. Assuming that the picker rotates in acounter-clockwise direction, as shown in Fig. 4, the

fan 50 would also be operated in a counter-clockwise direction as shown,the fan serving to blow the fibers free of the needles 24 and theflufied fibers between the top wall 40 of the casing and the picker 20into a feed chute 45. The feed chute 45 may comprise a top wall 42 whichforms a continuation of the top wall 40 of the casing and side walls 43which merge into the side wall portions 4| of the casing. The bottomwall 44 of the feed chute is suitably spaced from the top wall 42thereof to permit the free fiow of fibers suspended in the air currentpropelled by the fan 50. One end 45 of the bottom 44 of the feed chuteextends close to the outer end of the needles 24 so as to assist inremoving the fibers which might otherwise be carried completely aroundthe picker. The feed chute associated with the feed belt I and the feedchute associated with the feed belt la. lead into an enclosed passage 60and 60a respectively connected respectively to the headers BI and Bla,which in turn lead into a conduit or wind tunnel 62 and 62a throughwhich the fiufied fibers are conveyed.

Thus it will be seen that each picker unit comprises generally a picker20 with associated feed rolls 6 and I, presser blocks l2 and I3 and feedbelt, the fluifed pulp produced from the stock s being blown through a.conduit or wind tunnel. A sufiicient number of picker units to supplythe apparatus with the desired quantity of flufied stock may beprovided. I have therefore shown for purposes of illustration only twopicker units, one picker unit blowing the pulp through the wind tunnel62, while the other picker unit blows the flufled fibers through thewind tunnel 62a.

In the processing of such material as folded newspaper, waste paper andother fibers in connection with the manufacture of fiberboard, it ispreferable that picker units be provided in multiples of two so that apair of fans 10 and 10a are each supplied with a suflicient quantity offlufied pulp from the respective conduits 62 and 62a.

The fans 10 and 10a are so arranged as to supply the flufied fibers to apair of hollow condenser rolls 8| and 82, as shown more particularly inFig. 5. Condenser roll 8| is fixed to a suitable shaft 83 rotatablymounted in bearings 84 provided in the framework 80 of the machine. Thecondenser roll 82 is likewise fixed to the shaft 85 rotatably mounted inbearings 86 proin a clockwise direction while condenser roll 82 beingdriven in a counter-clockwise direction.

The fan 18, as shown in Figs. 5 and 6, is positioned on the right-handside of condenser roll 8| and extends approximately one-half the lengththereof. The fan 18a is positioned on the left-hand side of thecondenser roll 82 and extends approximately one-half the length thereof.Thus it is seen that the combined length of the fans 18 and 18a issubstantially equal to the length of the condenser rolls 8| and 82 sothat a layer of fibrous material of substantially uniform thickness isdeposited between the condenser rolls 8| and 82 when the fans 18 and18a, supplied with fibrous material from the conduits 82 and 82a, areoperated.

The fans 18 and 18a and condenser rolls 8| and 82 are enclosed in asuitable casing generally shaped as illustrated in Figs. 1, 5 and 6. Thefan. 18 is provided with an arcuate-shaped top closure wall 88 and anarcuate-shaped bottom closure wall 85, which merge into the contractedend 88 of the conduit 62. End closure wall 88 extends over one end ofthe fan 18 .and over the adjacent end of the condenser rolls 8| and 82.

The fan operates to throw the fibers upwardly along the arcuate top wall88 of the casing and thence down between the condenser rolls 8| and 82.The arcuate top wall 84 is provided with a portion 88 which extendsaround the periphery of the condenser roll 82 so that all of the fibersexpelled by the fan 18 will be deposited against the condenser rolls 8|and 82. The opposite end of the fan is enclosed by a side wall 88 sothat all the fibers fed into the casing surrounding the 0 fan 18 throughthe inlet port 83 is deposited between the condenser rolls 8| and 82 adistance approximately one-half the length thereof.

The fan 18a is also surrounded by a fan casing which is comparable tothe fan casing surrounding the fan 18, said casing comprising anarmate-shaped top wall 64a, an arcuate-shaped bottom wall 85a which isconnected to the contracted inlet 83a of the conduit 82a. One end of thefan 18a and adjacent ends of the condenser rolls 8| and 82 are enclosedby a side wall 86a. and the opposite end of the fan 18a is enclosed by aside wall 88a. The arcuate top wall 880 is provided with a portion 88awhich partially surrounds the condenser roll 8| over approximatelyone-half the length thereof so as to cause the fibers thrown upwardlyalong the arcu- Y ate top wall 84a to be deposited between the condenserrolls 8| and 82.

Each of the fans 18 and 18a may comprise a 50 drum or core portion 1| towhich is attached longitudinally extending blades 12. A shaft 18 uponwhich the fan 18 is mounted rotates in suitable bearings 14 provided inthe framework 88 of the machine. Similarly, a shaft 15 upon which fan 6518a is mounted likewise rotates in suitable bearings in the framework 88of the machine.

The fans 18 and 18a and condenser rolls 8| and 82 may be driven in anysuitable manner. For purpose of illustration I have shown a pulley wheel18 attached to the shaft 13 upon which a fan 18 is mounted, the pulleywheel 18 being driven by a belting 11 trained around the pulley wheel 18fixed to the shaft of the motor 28. The shaft 13 upon which the pulleywheel 18 is mounted may also be provided with a suitable drive orsprocket wheel 19 over which is trained a drive belt or chain 89operatively connected to the shaft 83 of the condenser roll 8| by meansof a suitable drive or sprocket wheel 88. The shaft 85 of condenser roll82 is driven by the gear 88 which meshes with gear 81 attached to theshaft 83 of condenser roll 8|. The shaft 85 of condenser roll 82 mayalso be provided with a drive or sprocket wheel 9| over which is traineda suitable drive belt or chain 82 operatively connected to the sprocketwheel 83 connected to the shaft 15 of thefan 18a. It will thus be seenthat the condenser rolls 8| and 82 and the fans 18 and 18:; may all bedriven in unison at the proper speed by means of the drive belt 11operatively connected to a suitable power source as the motor 28. It isunderstood that the gear and belt ratios are such as to drive thecondenser rolls 8| and 82 and the fans 18 and 180 at the properoperative speeds to properly take care of the fibrous material fed intothe fan casings through the ports 83 and 83a. The ports 88 and 63a arepreferably somewhat contracted, which serves to facilitate the movementof the fibers into the fan casing.

The condenser rolls 8| and 82 are provided with a large number of smallperforated holes extending through the shell thereof. These holes shouldbe closely spaced, preferably approximately or less apart, the holesbeing approximately to in diameter. The diameter of the holes as well asthe hole spacing will, of course, vary with the fibrous materialtreated. For example, fibrous material having relatively long fibers maybe suitably matted on the condenser rolls having holes of relativelylarger diameter and spaced farther apart than a fibrous mass composed ofrelatively short fibers.

Stationary suction tubes 88 are suitably connected to one or both endsof the condenser rolls 8| and 82 by means of a suitable leakproofconnection. The suction tubes 88 are suitably connected to a suction fanor suction pump 91 of well-known construction which serves to create apartial vacuum within the hollow condenser rolls 8| and 82, causing thepulp to adhere to the peripheral surface thereof and pass down betweenthe condenser rolls, as shown in Fig. 5.

The condenser rolls 8| and 82 should be spaced a sufficient distanceapart to permit the fibrous web formed thereby to pass therebetween. Thefibrous material passes into a suitable funnel 88 and is deposited upona conveyor belt 89 formed of foraminous material, such as canvas,foraminous textile, or papermaking wire. The belt 89 may be providedwith small pins or needles |88 to facilitate the removal of a mat offiuflcl fibers from the funnel 98. The up er end of the funnel 98 may beprovided with edge portions 88' which serve to peel off the fibrous massclinging to the condenser rolls 8| and 82. If desired, a slightlygreater suction may be applied either to condenser roll 8| or condenserroll 82 so as to cause the mass of pulp fibers to cling substantiallyentirely to any desired condenser roll. The conveyor belt 99 isrotatably mounted upon suitable guide rolls IN and I82, which arerespectively fixed to shafts I88 and I84 journaled in the frame I85 ofthe machine. The width of the belt 98 and the width of the funnel 98approximates substantially the full length of the condenser rolls 8| and82. If desired, however, the funnel 98 may be tapered to decrease orflared to increase the width of the web of fibers 5' deposited upon thebelt 99 to any desired width.

Suitable equalizing mechanism is provided in association with the funnel98 and/or the belt 99 for regulating the depth of the fiuifed fibrousmass deposited on the belt I00. For purpose of illustration, suchequalizermay'comprise a vertically adjustable partition I06, as shown inFig. 5, held to the funnel 98 by suitable adjustable screws I01 whichextend through vertical slots I08 in the partition I06. The lower endI09 of the partition I06 may be raised or lowered so as to space thesame the desired distance from the top run of the belt 99, thusregulating the thickness of the web s deposited thereon. Set screws I01retain the partition I06 in any desired adjustment position. Otherequalizer means other than that shown may be provided to regulate thethickness of the fibrous web s' deposited on the belt 99.

In event that small bits or chunks of stock .9 have not been entirelytorn to shreds by the picker 20, then the fibrous web s may be runthrough a second picker mechanism to reduce these bits of unshreddedstock s to the proper flutfed state so that all the fibers processedfrom the stock 8 are reduced to the desired fiuffed fibrous mass. Thesecond picker unit, shown in Fig. 5, may be similar in all respects tothe picker unit shown in Figs. 3 and 4 and heretofore described.Generally, this secondary picker I I mechanism may comprise acylindrical drum III approximately 24 to 36 inches in diameter andhaving a length substantially equal to the width of the finished web tobe made. The drum III may be formed from any suitable material, such aswood or metal, and is fixed to a shaft II2 which rotates in journals II3provided in the framework I of the machine. The drum III is providedwith needles or pins H4 projecting from the periphery thereof at adistance of approximately to 1% inches. The pins must be firmly mountedin the drum shell II I and should be formed of strong steel, so thatthey will not reak off, become loose, or otherwise become deformed. Thepins II4 preferably should not be spaced more than 1 inch apart, andpreferably should be spaced fairly close together, preferably beingspaced inch or less apart. The spacing of the pins as well as thelengths of the pins will be governed to a considerable extent by thestool: comprising the web s operated upon as well as by the paperboardto be produced. The pins are sharp at the outer end and are maintainedin sharpened condition by contact with-the fibrous web s. The shaft II2of the picker is provided with a suitable drive wheel II5 affixed to oneend thereof and operatively connected to drive wheel II6 fixed to theshaft of the motor 26 by a suitable belt connection H1. The picker isdriven so as to develop a peripheral speed of 2,000 to 10,000 linealfeet per minute. Where folded newsprint, paper waste or pulp fiberscomprise the web s, a speed of 5,000 to 7,000 lineal feet per minute hasproduced satisfactory results.

The felted stock 8' is drawn into the picker through the fluted feedrolls I2I and I 22, each provided with horizontally extending flutes orchannels I23. The fluted roll I22 is fixed to a shaft I24 rotatablysupported in fixed bearings I25 provided in the side frames I05 of themachine. The fluted roll I2I floats or rides over the felted stock sexerting a predetermined pressure thereon. The feed roll I2I is fixed toa shaft I26 which is free to float or move in a vertical direction apredetermined spaced distance from the periphery of the fluted roll I22,so as to take care of differences in the thickness of the web s'.

If desired, means may be provided to assist in retaining the fluted rollI2I in contact with the web s at all times with a predeterminedpressure. This may be accomplished by the provision of a pair of leverarms I3I, one end of each lever arm having an aperture therethroughthrough which the shaft I26 extends. The lever arms I3I may be providedwith a collar portion I32 through which a portion of the bearing or coreII3, upon which the picker H0 is mounted, extends. The bearing II3 thusserves as a pivot around which the collar portion I32 and the lever armsI3 I rotate. A weight arm I33 is fixed to each collar I32 and isprovided with adjustable weights I34 on the outer end thereof. By aproper adjustment of the weights I34, it is evident that the downwardpressure exerted by the roll I2I against the felted web s can beregulated and varied as desired.

This picker mechanism is also provided with means for compressing theweb at the point where the needles II4 engage the same, so that theentire web 5 will be reduced to the desired fiufied fibrous state, freefrom chunks or pieces of unseparated fiber. Such compression means maycomprise a pair of cooperating blocks or shoes MI and I42, between whichthe web .9"

passes. The faces I43 of the blocks I and I42 adjacent the picker pins 4are generally arcuate in shape so that there is little or no opportunityfor any unseparated fibers to pass between the block MI and the pickerneedles II4 without being thoroughly separated.

The block I42 may be fixed in stationary position by the angle supportsI 44 fixed to the side frame I05 of the machine. The top surface I 45 ofthe block I42 is at approximately the same level as the top of the feedroll I22, while the bottom I46 of the pressure block is at approximatelythe same level as the bottom of the feed roll I2I. The pressure block MIis also so constructed as to float on the stock 8. By way of example,block I4I may be provided with studs I48 projecting from the endthereof, which studs are attached or otherwise secured to the arms I3Iupon which the feed roll I2I is mounted. The feed rolls I2! and I22serve to draw the web s from the moving belt 09 in a direction towardsthe picker H0 and to force the web between the pressure blocks HI andI42, the adjacent walls I45 and I46 of which are so beveled as tofacilitate the movement of the web s therebetween. The side wall facesI49 of the blocks MI and I42 are also slightly arcuate in shape so as tosubstantially conform to the peripheral contour of the feed rolls I2Iand I22.

A fan I60 is provided to force the fluifed fibers around the arcuatecasing I and into the tunnel Ill. The fan I60 may comprise a core or adrum IGIupon which the horizontally extending blades I62 are secured.The fan is mounted on a shaft I03 fixed to the core I6! and the shaft isrotatably supported in suitable bearings I64 provided in the framework I05 of the machine. Both the fan I60 and the picker H0 rotate in acounter-clockwise direction, as shown in Fig. 5. The casing has a topwall I70 extending over the top portion of the picker H0 and over thetop portion of the fan I60, and thence down around the feed roll I2I.The top wall "0 may merge with the side walls I05 of the machine so asto completely enclose the picker 0, the fan I60, the feed rolls I2I andI22 and the pressure blocks HI and I42. Since the framework I05completely enclosed rests upon the floor, there is no opportunity forthe fibers or fiber dust escaping from the picker 0 and circulating inthe room. The flufied fibers separated from the web s by the needles II4pass around the interior of the top casing I10 and are blown by the fanI60 into the tunnel "I. The tunnel "I may comprise a top wall I12, abottom wall or floor portion I13, enclosed at the sides by the enclosingwalls I14. The bottom wall I13 has the inner end I15 thereof extendingclose to the outer end of the needles II4 so that the fibers will droponto the floor I13 or into the tunnel Ill.

The picker mechanism above described is preferably driven from thesingle motor 26 by the drive belt II1, so that all parts of the machinewill operate together in complete synchronism. The feed rolls l2I andI22 are preferably driven by the motor 26 in unison with the picker IIO.Such a drive mechanism may comprise a drive or sprocket wheel I5Iattached to the shaft I26 of the feed roll I2 I. The sprocket wheel I5Iis operatively connected to a sprocket wheel I52 fixed to the shaft 2 ofthe picker IIO by means of a suitable belt chain I53 through a suitablespeed reducer. Along tooth gear I28 fixed to the shaft I24 of the feedroll I22 meshes with a long tooth gear I29 fixed to the shaft I26 of thefeed roll I2I so as to drive the feed rolls I2I and I22 together. Theteeth on the gears I28 and I29 are preferably of sufiicient length so asto always maintain a meshing contact irrespective of the floatingmovement of the feed roll I2I. The supporting roll I02 supporting thebelt 99 may likewise be driven in unison from the motor 26 by means of asuitable drive belt or chain I06 trained around a sprocket I01 fixed tothe shaft I04 of the roll I02. The chain I06 is trained around thesprocket I08 of the drive shaft I24 of feed roll I22. The fan I60 may beoperatively connected to the shaft II2 of the picker by means of a beltI61 trained over a pulley wheel I68 fixed to the shaft I63 of the fanI60 and also trained over a pulley wheel I69 fixed to the shaft II2 ofthe picker IIO. Thus, it is seen that the picker IIO, the fan I60, thefeed rolls I2I and I22 and the conveyor belt I20 may all be driven fromthe driving motor 26.

The separated substantially dry fiuffed fibers blown into the tunnel I1Iare brought into contact with condenser mechanism which mats the fibersinto a web of the desired width and thickness. A condenser mechanism Imay comprise a condenser roll I8I mounted to rotate in a clockwisedirection, as shown in Fig. '7, upon a suitable shaft I82 which rotatesin the bearings I83 provided in the framework I84 of the machine. Thecondenser roll I8I is provided with a large number of holes or openingsI85 and one or both ends of the roll is connected to a suitable conduitI86 which in turn is connected to a suction fan I81. When the machine isin operation the suction or partial vacuum created by the fan I81 drawsthe flufied fibers onto or against the periphery of the condenser rollI8I serving to mat the same in a web of predetermined thickness. Thecondenser roll I8I may operate in conjunction with a companion condenserroll, as the condenser rolls 8| and 82 shown in Fig. 5. The condenserrolls so arranged rotate to feed the fibers therebetween and lay them ina predetermined web or mat.

I have also found that in place of a pair of condenser rolls, a suitablemoving foraminous sheet or layer, such as canvas or papermaking wire,may be substituted for the condenser roll. As shown in Fig. 7, canvas orpapermaking wire I89 trained over the guide rolls I90 and I9I supportsthe top run of the condenser belt I89 in desired spaced relationshipfrom the periphery of the condenser roll I8I. The supporting rolls I90and I 9| are suitably fixed to shafts I92 and I93 respectively, whichrotate in suitable bearings provided on the framework I84 of themachine. A suction or vacuum chamber is positioned below the belt I89 soas to draw the fibers into matting contact with the top run of the beltI89. Such vacuum chamber may comprise front wall I94, rear wall, sidewalls I96 and bottom wall I91, so constructed as to create unequalpressure with respect to the opposite sides of the top run of the beltI89, causing the fibers to be drawn down against the top run of thebelt. The vacuum chamber above described is suitably connected to thesuction fan I81 as by a suitable conduit I98. Preferably, the suctionapplied to the upper run of the belt I89 is somewhat greater than thesuction applied to the surface of the condenser roll I8I, so as toinsure that the fibers will cling to the belt I89 and leave the surfaceof the condenser roll Ill. It is understood, however, that a secondcondenser roll may be substituted for the foraminous belting I89 orother suitable screen or suction device provided to cause the fibers tomat into the desired web.

The top wall I 12 of the tunnel I1I extends around the condenser rollI8I as shown in Fig. '1, and the side walls I 14 of the tunnel extendover the ends of the condenser roll I 8| so as to completely enclose thesame. The bottom wall or floor I13 of the tunnel I1| extends to theperiphery of the supporting roll I90 of the belt I89.

It has been found that complete uniformity in the thickness as well asin the width of the web s emerging from the condenser mechanism I80 maybe obtained by providing wings I16, as shown moreparticularly in Fig. 8,in association with the side walls I14 of the tunnel MI. The wings I16are attached to the side walls I14 immediately in advance of thecondenser roll I8I and adjacent to the fioor I13. The wings I16 serve toinsure the even distribution of the fibers over the top run of the beltl89 as it emerges over the condenser roll II. The transforma tion of theweb 3 comprising the substantially dry, loosely fiuffed, separatedfibers into a compact fiberboard material of the desired strength andthickness then begins.

As shown more particularly in Figs. 7 and 8, the web s of loosely piledfibers leaves the condenser belt I89 and moves onto the horizontal runof a continuous belt 2I0 formed of canvas, papermaking wire, or otherforaminous material. The belt 2l0 is trained over a pair of guide rolls2 and 2I2 so that the belt moving therebetween will present asubstantially horizontal table-like surface. The guide shafts 2I3 and 2respectively, are mounted in suitable bearings 2I5 provided in theframework 2 I 6 of the machine, which will hereafter be termed afelter." A guide roll 2I1 fixed to a shaft 2I8 rotatably mounted insuitable bearings provided in the framework 2I6 guides the belt from thesupporting roll 2I2 to the supporting roll 2 I3. To facilitate theremoval of the web s from the suction conveyor belt I89,

I provide a suitable blade or platform 220 which is positioned betweenthe roller I9! and the roller 2!!, causing the web to leave the conveyorI89 and pass onto the conveyor belt 2I0.

The binding solution is applied to the web as it moves along upon thebelt 2). The binding solution, preferably containing the properproportions of ingredients, is placed in the mixing containers 225 or226, provided with a suitable mixing paddle 221. The mixed solutionpasses through the conduits 228 into a suitable float valve box 229. Afloat valve 230 connected to the pipe-line 228 and positioned in the box229 may be provided to regulate the fiow from the mixer as desired. Itwill be appreciated that as the contents are drained out of thecontainer 225, for example, more solution material can be prepared andmixed in the container 226. The float valve regulates the flow of thebinder solution into the box 229, the float valve serving to maintainthe desired head or pressure in the supply pipe 232. -Shut-oif valves23! in the pipe-line 228 may be provided to regulate the flow from themixers.

The binder solution flows from the supply pipe 232 into suitable spraynozzle mechanism. For the purpose of illustration only I have shown aspray nozzle conduit 233 connected with the supply pipe 232, the conduit233 having spray nozzles 234 associated therewith. The binder solutionis forced out through the nozzles 234 by means of air pressure suppliedby the air line 235. The nozzles 234 are so arranged as to thoroughlyimpregnate the web s with a binder solution. The spacing of the nozzles234, as well as their distance above the web s will depend upon theirtypes and construction, the object being to obtain the desiredimpregnation without blowing holes or cavities into the moving web $5. Ihave found that air nozzles should project a fine spray under from 2 to15 lbs. pressure which, of course, may vary with the distance of thenozzles from the web as well as the distance of the nozzles from thefloat valve box 229. Sufficient impregnating solution should beprojected by the nozzles 234 to thoroughly impregnate the web and tocoat each individual fiber with the binder solution.

Only suflicient binder solution should be projected to thoroughlyimpregnate the web without causing the binder to float the fibers or insuch quantities as to cause the solution to drip or run off from theweb. In event that any of the solution drips from the web when pressureis applied thereto, as will hereafter be described, such material can becollected in a suitable tank 238, as shown in Fig. 7. The solutioncollected in tank 238 can be filtered and reused. It is here pointedout, however, that it is not desirable to use such excessive quantitiesof binder solution as will cause any appreciable quantity of thesolution to drain off from the web 8 The impregnated web which leavesthe nozzles 233 will now be designated The impregnated web 5 passesunder compressing devices to gradually compress the web in a firm,compact layer, the pressure being so regulated as to retain the binderwithin the web and particularly Within the interior thereof. Forpurposes of illustration, I have shown in Figs. 7 and 8 a pressure roll24! fixed to the shaft 242 rotatably mounted in suitable bearings 243provided in the framework 2! 6 of the machine. The roller 24! serves tosupport the upper run of the conveyor 2). A second roll 244 whichcooperates with roll 24! is positioned directly over the roll 24!. Theroll 244 is fixed to a. suitable shaft 245 rotatably mounted at each endthereof in a suitable bearing block 246 at each end of the roller. Eachbearing block 246 is movable vertically in a suitable guide frame 241and may be supported therein in any desired adjusted position by asupporting screw 248 fixed to the block 246 and threaded through theguide frame 241. The roller 244 has trained thereover a compressor belt250 which may be formed of papermaking wire or other foraminousmaterial. The compressor belt 250 passes around a second compressor roll25! positioned directly over the compressor roll 2I2, heretoforedescribed. The roller 25! may be fixed to a suitable shaft 252, whichmay be rotatably supported in brackets 253 extending from the supportingframe 2I6 of the machine. If it is desired, the roller 25! may beadjustably mounted by providing a slidable bearing block, guide frameand adjusting screw similar to the bearing block 246, the guide frame241 and adjusting screw 248 associated with the compressor roll 244. Thelower train of the belt 250 contacts the upper surface of the saturatedweb s which is disposed between the belts 2! II and 250. The compressivepressure exerted upon the web s can be regulated by manipulating theadjusting screws 249 so that the desired compressive pressure can beexerted upon the saturated web s passing between the belts.

The conveyor belts 2!!! and 256 are preferably driven from the centralpower plant or motor 26 and may be operatively connected thereto by anysuitable means of power transmissions, such as belts and pulleys and/ortrains of gears. In actual practice gear drives are generally preferreddue to the fact that they are more positive in operation. For purposesof illustration only, however, I have shown one form of driveconnection, although it is understood that my invention is in no waylimited to the drive arrangement shown. The shaft I93 supporting theconveyor belt I89 may be provided with a suitable sprocket wheel 26!connected to sprocket wheel 263 fixed to the shaft of the fan I81through a suitable chain drive connection 262. The fan shaft I 88 may beprovided with a suitable sprocket or pulley wheel 264 connected by meansof a chain belt 265 to the sprocket wheel 266 fixed to the shaft II2 ofthe secondary picker H0. The shaft 2I3 of the roller 2!! supporting theconveyor belt 2!!! is provided with a sprocket wheel 261 connected tothe sprocket wheel 268 of the driven shaft I93 through a suitable chainbelt 269. The supporting roll 2I2 is also preferably positively driven.

I have shown for purposes of illustration a sprocket wheel 219 fixed tothe shaft 2I4 upon which the supporting roll 2! 2 is mounted. Thesprocket wheel 21!) is operatively connected to the sprocket wheel 21!fixed to the driven shaft I93 through suitable chain drive 212. Theshaft 252 which carries the roll 25! may be driven by a suitablesprocket wheel 213 attached to the shaft 252 and connected to a sprocketwheel 214 fixed to the shaft 2I2 through a suitable chain drive 215. Itwill be understood that the entire mechanism, including the rolls l! and2I2 supporting the belt'2l0, the rolls 25! and 244 supporting the belt250, the roll I9! supporting the conveyor belt I89, the condenser rollI8! the suction fan I81, are all positively driven from the single motor26 through suitable drive mechanism which preferably should be apositive gear made of any desired length and provided with suitableweb-supporting devices therein. Heating means are provided in the tunnelto assist the escape of the liquid and volatile constituents. When thedry web emerges it may be calendered or otherwise treated to produce thedesired surface finish.

More particularly the drying tunnel may comprise a housing enclosurecomprising enclosing side walls 29l, 292, 293, and 294, a top wall 295and, if desired, a bottom wall 296. The drying tunnel has mountedtherein a series of conveyors so arranged as to support the web andconvey the web from one conveyor to the other. I have shown in Fig. 7 aseries of five such conveyors each comprising a continuous supportingbelt which are respectively designated 296a, 2961), 2960, 296d and 296e.Each belt conveyor is supported on a pair of hollow rolls 291 and 298which preferably are drier drums. Each of the hollow drums 291 and 298comprises a cylindrical wall 390 having secured at the ends thereof anend closure having a steam admission or outlet opening 302 extendingthrough the hub portion 303 thereof. The hub portions 303 are rotatablymounted in suitable bearings 304 provided in a suitable framework 305positioned along the side walls 292 and 294 of the tunnel drier. A steaminlet pipe 306 is provided with branch conduits 30! extending therefrom,each branch conduit being connected by universal fitting 308 to the hubportions 303 at one end of the drier drums.

The steam enters the drier drums 291 and 298 associated with each of thesupporting belts 296a, 296b, 296e, 296d and 296e, the steam heating theinterior of the drier drums and the tunnel to the desired temperature soas to dry the web supported therein and assist the escape of thevolatile constituents. The partially condensed steam escapes through theother end of the drier drums through suitable branch conduits 3connected to the adjacent hub portions 303 of the drier drums by meansof a suitable universal connection 3l2. The partially condensed steam isdrawn out through the conduit 3l3 connected to the branch conduits 3i I.Suitable thermostatic controls and other automatic devices may beprovided to regulate the temperature of the steam within the drier drums291 and 298 as well as the temperature within the drying tunnel itself.

The compressed saturated web s" is conveyed to the drying tunnelpreferably by means of a suitable belt conveyor. The conveyor belt 3| 5may comprise a continuous belting of suitable foraminous material, suchas canvas, which is trained over a supporting roll 3! 6 supported by asuitable shaft 3 I! mounted in suitable bearings 7 3l8 provided in theframework 216 of the felter mechanism. The conveyor belt 3l5 leads tothe tunnel drier and is trained over a roll 32| fixed to a shaft 322which may be rotatably mounted in suitable brackets 323 fixed t0 theframework of 75 the tunnel drier.

' able arrangement of heated coils.

The saturated compressed web s is conveyed by the conveyor belt 3 I 5 tothe tunnel drier where it is deposited upon the conveyor belt 298awithin the tunnel drier. The saturated compressed web a has a certaindegree of tensile strength and is in fact self-supporting forconsiderable length. In view of this characteristic there is nodifliculty in transferring the compressed web s from the feltingconveyor 2|. to the conveyor 3l5 and onto the tunnel or drying conveyor296a. It will be noted by referring to Fig. 7 that the compressed webpasses through a suitable opening 325 in the tunnel drier and isdeposited on the drier belt 298a, where it is conveyed until it dropsupon the upper run of the drier belt 29Gb which conveys it in theopposite direction until it drops onto the conveyor belt 2960. Theconveyor belt 2930 moves the drying web to the left, as shown in Fig. 7,until it drops onto conveyor belt 296d which conveys the drying web tothe right until it drops onto conveyor belt 296a which conveys thesubstantially dried web to the left and out through the dischargeopening 328 pro vided in the side wall 293 of the tunnel drier.

The drying web may be given any desired number of loops within thetunnel drier as is necessary to eifect the dwired drying action. Ifdesired, the tunnel drier may be positioned at a lower level than thefelting mechanism so that the conveyor belt 3l5 may be positionedsubstantially in a horizontal plane, so that less strain is exerted onthe compressed web s as it is transferred from the felting mechanism tothe tunnel drier. It is also understood that other drying means thansteam heated drums may be provided within the tunnel drier, such as anysuit- A suitable funnel 321 may be provided in the top wall 295 of thetunnel drier through which the volatile constituents are carried away.

The drying drums 291 and 298 and the conveyor belt 3|5 are preferablydriven in unison from a single source of power, such as the motor 26. Byway of example, the shaft 3!! upon which the roller 3| 8 is mounted, maybe provided with a sprocket wheel 216 connected to a sprocket wheel 218fixed to the shaft 2 of the roller 2l2, the shaft 2 being driven in amanner heretofore described. The opposite end of the shaft 3| 1 isprovided with a sprocket wheel 3i9 operatively connected through a drivechain 320 to a sprocket wheel 330 fixed to the shaft 322 of the roll 32I. Thus the conveyor belt 3l5, through a suitable train of drivingmechanism, is operatively connected to the motor 26. A second sprocketwheel 33! fixed to the driven shaft 322 is connected by means of a drivechain 332 to a sprocket wheel 333 connected to the hub portion 303 ofthe driving drum 298. The hub portion 303 of the drying drum 298 whichcarries the belt 298a is provided with a gear 333 which meshes with agear 335 fixed to the hub portion 303 of the drier drum 299 whichcarries the belt 2961). The hub portions 303 of each of the drier drums298 which respectively support the belts 2960, 296d and 29Be are alsoprovided with suitable intermeshing gears so that all of the conveyorbelts can be driven by the single sprocket wheel 333 attached to the hubportion 303 of one of the drums 298. Thus it is seen that the drierdrums 298 by means of the connecting belting 296a, 296b, 2980, 296d and298s will drive the associated drier drums 291 in the proper direction,as shown by the arrows in Fig. '7. All of the drier drums 291 and 298may thus be connected through suitable driving mechanism to the drivingmotor 26.

The dried web which emerges from the tunnel drier will hereafter bedesignated s The compressed, impregnated and dried fibrous material 8has now been reduced to the desired board material and can be given asurface finish by passing the same through a calender stack, as shown inFig. 2. The calendar stack 340 is provided with any desired number ofsuperimposed rolls, as rolls, 342, 343, 344, 345 and 346. The board 3passes between calender rolls 342 and 343, and thereafter passes betweenthe successive calender rolls 344, 345 and 346, each calender rollexerting the desired calendaring and finishing pressure on the boardsurface. The calenders may, if desired, be heated, although this is notgenerally necessary in the manufacture of fiberboard products. Thefinished and calendered board, hereinafter designated as s, may eitherbe put into cylindrical rolls or cut into sheets of the desired widthand length.

In certain types of board used for box liners, packing cases, cardboardor paperboard boxes, it is sometimes desired to cover the board 8 with asuitable surfacing layer, such as a sheet of white or colored paper.Such paper surface is generally applied only to one side of the board.For purposes of illustration, I have shown in Fig. 7 a roll of paper orother desired sheeting material 350 rotatably mounted upon a suitableshaft 35L The sheet is placed in contact with the upper surface of thecompressed, saturated web 5 and adheres thereto by reason of the bindersolution impregnated into the web. The movement of the web s over theconveyer belt 3l5 causes the paper 350 to unwind and lie smoothly on theweb s If desired, a compressor roll 352 positioned directly over theguide roll 32| may be provided to press the sheet drawn from the roll350 into firm adhering contact with the web s. The pressure roller 352may be fixed to a shaft 353 mounted in suitable bearings so as to exertthe desired pressure against the sheet superimposed over the web s Otherwell-known coatings may be applied to the web 3 as it passes over theconveyor belt 3 l5. For example, wood flour dust, China clay, talc, andflock of all kinds may be dusted over the surface of the moving web 8Surfacing treatments may also be given to the finished material as. itemerges from the tunnel drier.

The impregnated solution projected by the nozzles 233 into the looselyflufied web s may comprise well-known paper sizing formed of suchconstituents as resins, caseins, glues, starches, and similar adhesiveor binding materials either used alone or mixed. The ingredients mixedwith the desired amount of carrier liquid, such as water, are placedwithin one of the mixing containers 225, and the desired batch is mixedup by operating the paddles 221. When the desired mix has been obtainedthe valve 23l associated with the mixing chamber 225 is opened,permitting the mixed material to flow into the receptacle or float box229, and thence to the spray nozzles 233 under the desired headpressure. When fiberboard material, sometimes known as paperboard,cardboard, or pulp board, is to be manufactured, the usual bindingingredients used in present processes may be provided. The usualfiberboard binding ingredients, such as starches, resins, caseins,glues, latex and similar binding ingredients, are sprayed through thenozzles at approximately room temperature, and

the volatile constituents are removed in a heated drying tunnel. In themanufacture of wallboard from such fibrous materials as bagasse,however, other binding ingredients may be used, such as emulsifiedasphaltum or tar, heated sulphur, may be used either alone or mixed withother binding ingredients. The emulsified asphaltum or tar may besprayed into the fiberboard also at approximately room temperature andthe volatile constituents removed in the heated drying'tunnel. Where theasphaltums and tars are not emulsified, they preferably should beprojected into the fibrous web in a heated, free-flowing condition andthe impregnated web is thereafter cooled in the tunnel dryer by forcingcold air or a cold liquid through the hollow drying cylinders 291 and298, or by eliminating the drying tunnel entirely and blowing cold airover the impregnated web. In the manufacture of wallboard, it ispreferable to add to the binder constituent a preparation or chemicalobnoxious to vermin and rodents which sometimes attack the fibrousmaterial such as bagasse. Thus an improved wallboard which is bothvermin and rodent proof may be produced by the method and apparatusherein described.

While the method and apparatus as herein illustrated and described isparticularly adapted for the manufacture of cardboard, paperboard, pulpboard and fiberboard, it is understood that the process and apparatusmay be modified as desired to manufacture other sheeted products.Certain changes can also be made in the apparatus herein describedwithout departing from the spirit of this invention. It is furtherunderstood that where the term conveyor is used, various different formsof conveyors, moving belts, moving cylinders, or platforms may be usedinterchangeably. The selection of the particular conveyor used will begoverned somewhat by the character of the fibrous material handled andthe finished product to be made. The various operating mechanismscomprising the feed rolls, pickers, fans, condenser ro condenser belts,conveying mechanism, felting mechanism and dryer may be variously drivenbut should all be driven in synchronism to avoid any strain being placedupon the web as it passes through the apparatus.

Fiberboard products, such as cardboard, paperboard and pulp board, canbe manufactured from newsprint, waste paper and like fibrous products,at greatly reduced cost over present processes of manufacture. Underpresent process of manufacture of these products from the above rawmaterials, a plant investment of approximately $20,000.00 or more perton per day is required, as compared with a plant investment using myimproved process and apparatus of approximately $2,000.00 per ton perday, the above figures covering only equipment and erection costs. Manytimes the floor space is also required under present processes ascompared with the floor space required for operating my process andapparatus. Under present commercial processes the power consumedapproximates roughly 40 horsepower per ton per day, whereas my processand 'apparatus can be operated with approximately four horsepower perton per day. Under present processes approximately six times the amountof labor is required co'.-ipared with my process. Furthermore, the largevolume of pure water having the proper chemical constituent with thenecessary equipment to handle the same, required under presentcommercial processes, is

entirely eliminated. Reduced overhead costs, the proximity to the sourceof supply of raw material, or the market, permit of further savings andflexibility in manufacture. My process can be carried out without regardto temperature, humidity, or other climatic conditions, and can beinstalled at widely scattered points, with proper regard both to rawmaterial sources, markets, lowcost power, and transportation costs. Thesavings and advantages which my process possesses over presentcommercial processes is readily evident to those skilled in the art.

While certain novel features of the invention have been disclosed andare pointed out in the annexed claims, it will be understood thatvarious omissions, substitutions and changes may be made by thoseskilled in the art without departing from the spirit of the invention.

What is claimed is:

1. Apparatus for manufacturing fiberboard from substantially dry fibrousstock including in combination, means for mechanically reducing saidfibrous stock into a loosely piled mass of fibers, said fiber-reducingmeans including, a rotatably mounted drum, sharpened pins projectingfrom said drum spaced less than one inch apart, power means for drivingsaid drum at a peripheral speed of 2,000 lineal feet per minute andupwards, and cooperating elements for retaining said stock in arelatively hard compacted layer while operated upon by said pins, meansincluding cooperating suction elements for establishing a predeterminedunstratified layer of said substantially dry loosely piled fibers, meansfor projecting a binder into said loosely piled uncompacted layer, andmeans for compacting said layer into a self-sustaining web.

2. Apparatus for forming cardboard, paperboard, pulp board and likefiberboard materials including in combination mechanism for reducingsaid stock to a substantially dry loosely piled fiuffed condition,, saidmechanism including a drum having flufiing pins projecting from theperiphery thereof, power means for driving said drum at a peripheralspeed of 2,000 lineal feet per minute and upwards, and compressionelements for retaining said stock in a relatively hard compacted layerwhile operated upon by said pins, means including a suction drum forestablishing a loosely piled layer of predetermined thickness of saidfiuffed fibers, and means for introducing a binder component into saidloose- 1y piled uncompacted layer.

3. Apparatus for forming cardboard, paperboard, pulp board and likefiberboard materials from fibrous stock including in combinationmechanism for reducing said stock to a substantially dry loosely piledfiuffed condition, said mechanism including a series of finding pins,means for driving said fiufling pins transversely across the stock, andcompression elements for retaining said stock in a relatively hardcompacted layer while operated upon by said pins,

suction means including a suction drum for establishing a loosely piledlayer of predetermined thickness of said fiuffed fibers, and means forintroducing a binder component into said loosely piled fluffed fibrouslayer.

4. Apparatus for manufacturing fiberboard from newsprint, paper wasteand like fibrous stock which includes, a fiber-flufiing device includinga drum, fiuffing pins projecting from the periphery of said drum, meansfor rotating said drum at a peripheral velocity of from 2,000 to 10,000lineal feet per minute, cooperating feed rolls for feeding said stock tothe periphery of said rotating drum, cooperating compression elementsbetween said feed rolls and said drum for compressing the stockimmediately adjacent said fiufilng pins in a firm layer, means forestablishing a loosely piled layer of the fibers removed by the pinsfrom said stock, and means for introducing a binder into said looselypiled layer.

5. Apparatus for manufacturing fiberboard from newsprint, paper wasteand like fibrous stock which includes, a fiber-fiuffing device includinga series of closely spaced sharpened pins, means for feeding the stuckinto engagement with the sharpened points of said pins, means for movingsaid pins transversely across the advancing stock, means comprisingrelatively stationary shoes extending into close proximity to said pinsfor compressing and retaining the stock in a firm layer while individualfibers are removed from the stock by said pins, means for establishing aloosely piled layer of the fibrous material removed from the stock bysaid pins, and means for impregnating said loosely piled layer.

6. Apparatus for manufacturing fiberboard from newsprint, paper wasteand like fibrous stock which includes, means for reducing said stock toa substantially dry loosely piled arrangement of the constituent fibers,means for establishing a substantially dry layer of said loosely piledfibers, said means comprising a pair of perforated cylinders, suctionmeans for causing the fibers to mat on one or both of said cylinders,means for rotating said cylinders so as to pass the layer therebetween,means for removing the layer from said cylinders, a belt conveyor, meansfor distributing the fibers removed from said cylinders into acontinuous mat of predetermined thickness, and means for impregnatingsaid substantially dry layer with a binder.

'7. Apparatus for manufacturing fiberboard from newsprint, paper wasteand like fibrous stock which includes, means for reducing said stock toa substantially dry loosely piled arrangement of the constituent fibers,means for establishing a substantially dry layer of said loosely piledfibers, said means including a hollow cylinder having a perforatedcylindrical surface, a foraminous belting, suction means applied to saidcylinder and said foraminous belting and operative to apply a greatersuction to said foraminous belting so as to cause the constituent fibersto deposit thereon, means for spreading said fibers in a layer ofpredetermined thickness, and means for impregnating said layer with abinder.

8. Apparatus for forming fiberboard from newsprint, paper wastearid-like fibrous stock which includes mechanism for reducing said stockto a substantially dry loosely piled fiufied condition, a casing, aseries of movable fluffing pins positioned within said casing, powermeans for driving said pins at a peripheral speed of 2,000 lineal feetper minute and upwards, and compression elements for retaining saidstock in a relatively hard compacted layer while operated upon by saidpins, means including rotatably mounted blades for driving the looselyfluffed constituent fibers through said casing, means for establishing apredetermined layer of said fiuffed fibers, and means for impregnatingsaid fiuffed fibrous layer with a binder.

' HORACE A. SHEESLEY.

